Method for preparing an alpha alumina catalyst support



United States Patent 3,392,125 METHOD FOR PREPARING AN ALPHA ALUMINA CATALYST SUPPORT Allan C. Kelly, Palo Alto, Hebon J. Ducote, Saratoga, and Leo R. Barsotti, San Mateo, Calif., assignors to Kaiser Aluminum & Chemical Corporation, Oakland, Calif., a corporation of Delaware No Drawing. Filed July 11, 1963, Ser. No. 294,231 13 Claims. (Cl. 252-461) ABSTRACT OF THE DISCLOSURE Alpha alumina shaped particles having a pore volume distribution such that a major portion of the pores have a diameter greater than 580 A. and having a crushing strength exceeding pounds per particle, said strength based on 6 x 8 mesh particles. The procedure for producing such particles and their use as support material for oxidizing catalysts is also disclosed.

This invention relates to novel alumina shaped particles or bodies which are suitable for use as support material for catalysts, particularly for catalytic oxidation of carbon monoxide and hydrocarbons such as contained in automotive exhaust gases. More particularly it relates to novel alpha alumina shaped particles characterized as having improved resistance to abrasion, improved crushing strength and a large pore diameter and to oxidizing catalysts made therefrom, and further to an improved method for the preparation of the shaped particles from alumina hydrate such as is obtained by precipitation from sodium aluminate in the well-known Bayer process.

Exhaust gases from gasoline or diesel engines which are discharged to the atmosphere contain substantial quantities of unburned hydrocarbons and other undesirable combustion products. The exhaust gases comprise, for example, nitric oxide, sulfur dioxide, carbon monoxide and unburned hydrocarbons. Air pollution studies reveal that some of the combustion products of exhaust gases, primarily nitrogen oxide and unburned hydrocarbons, react with atmospheric oxygen in the presence of sunlight to pollute the atmosphere with smog which contains noxious irritants detrimental to comfort and health. Accordingly, extensive studies have been undertaken to find means to minimize the smog-forming potential of such gases.

Various schemes have been heretofore investigated for removal of these noxious compounds from exhaust gases. Changing of the design of gasoline engines to effect better combustion has been attempted. Also, flame afterburners to convert the unburned hydrocarbons by burning have been tried. However, none of these schemes have proven to be an adequate answer to the problem.

Investigators have turned to catalytic oxidation means for treating such gases to prevent air pollution. The destructive conversion of exhaust gases by catalytic treatment can be fundamentally accomplished in a small unit with inexpensive materials of construction. However, to translate the catalytic oxidation process into a practical and useful scheme for treating exhaust gases from internal combustion engines, a number of problems must be overcome, chief among which are the development of a carrier or base material for the oxidation catalyst that has high strength and high resistance to abrasion, as well as high temperature stability when impregnated with catalyst to resist reaction with the impregnant, and the development of suitable oxidation catalysts that have good catalytic activity at low temperatures after exposure to high temperatures and are not particularly susceptible to poisoning ice by lead salts and other gasoline additives found in the exhaust gases.

Inorganic metal oxides, such as silica, magnesia, titania and the like, have been used for many years as a carrier material for catalysts and, in some instances, as a catalyst itself. Active alumina in the form of pellets, cylinders and nodules has been used as a carrier or base for catalysts, and is often selected in preference to other materials because it is relatively inert and will maintain a comparatively high surface area over the temperature range normally encountered in many catalytic reactions. The active aluminas useful for catalyst support material have been prepared by various methods. For example, alumina trihydrate precipitated in the Bayer process may be ground and then heated at about 300 C. for about 2 hours followed by impregnating the active alumina with a catalyst. Then, too, active alumina that is useful as a support for catalysts has been prepared by reacting aluminum metal with a partially miscible alcohol, such as amyl alcohol, to form aluminum alcoholate. The aluminum alcoholate is hydrolyzed in the presence of ammonium hydroxide and carbon dioxide, calcined at temperatures of above about 400 C. and impregnated with a catalyst. The physical and chemical properties which active aluminasv possess are strongly dependent on the procedures followed in their preparation. Consequently, the active alumina art is highly developed and is replete with disclosures for various manufacturing methods for optimizing certain characteristics of active alumina. Although active alumina has proved to be satisfactory for many purposes, its use, however, as a base or carrier in catalytic oxidation processes has not been entirely satisfactory. For example, the prior art active aluminas when impregnated with a catalyst do not possess the required high temperature stability to resist reaction with impregnants.

The active alumina shaped particles may be calcined to transform the active alumina partially or completely to alpha alumina at high temperatures l000 C. or higher), however, the shaped particle, after the transformation from active alumina to alpha alumina, sufiers an almost complete loss in strength and is easily crumbled by hand. Consequently, these alpha alumina shaped particles have not heretofore been usable as carriers or bases for oxidation catalysts because of the lack of strength.

According to the instant invention, there is presented superior and improved alpha alumina shaped particles that have high temperature stability, relatively large diameter pores, as well as a high resistance to abrasion and a high crushing strength. The pore characteristics are such that a major portion of the pore volume is made up of pores having a pore diameter greater than 580 A. (angstrom units). By pore volume is meant the total void' space including both intra and inter crystalline voids. The crushing strength of the shaped particles exceeds 10 pounds per nodule, said strength based on 6 x 8 mesh (Tyler Screen Scale) nodules. Preferably, the crushing strength exceeds '15 lbs. per nodule. The alpha a-umina of the invention can be produced by a particular and novel sequence of steps comprising flash calcining alumina trihydrate at temperatures above about 800 C. for a relatively short time, such as from a fraction of a second to ten seconds, to form active alumina comprising a mixture of chi and rho forms, forming the active alumina with water into shaped particles, and hardening the alumina until it becomes a self-sustaining mass, converting a major portion of the rehydrated alumina to an alumina phase of boehmite of pseudoboehmite, or mixtures thereof, and most important, calcining the alumina at a temperature in excess of about 1000 C. for a period of time 3 sufiicient to convert the transition alumina to alpha alumina and to develop pore characteristics wherein a major portion of the pore volume is constituted of pores having a diameter greater than 580 A.

The novel alpha alumina shaped particles manufactured by this process are particularly suitable as a base for oxidation catalysts in a system which requires the catalyst carrier to have a high crushing strength, high resistance to abrasion as well as pore characteristics as previously described. Furthermore, this invention provides for the adsorption of suitable oxidation catalysts on the novel alpha alumina carrier. It has been found that these catalysts when applied to the novel carrier of the invention are particularly effective for oxidizing the unburned hydrocarbons and carbon monoxide contained in automotive exhaust gases.

Other features and advantages will become apparent from the ensuing disclosure.

By practice of the instant invention, alumina trihydrate obtained from the Bayer process, i.e., Al O .3H O, referred to as gibbsite alumina, is partially calcined by permitting it to fall into and rapidly pass through a flame, or hot gas stream issuing therefrom and maintained at a high temperature, for example, on the order of 800 C. or higher. The residence time of the powdered gibbsite alumina in the flame or hot gases in short and may be, for example, from a fraction of a second to about seconds. The resulting calcined active alumina particles are then separated and recovered from the flame or exhaust gases. X-ray diffraction analysis of the resulting transition alumina particles has indicated that they are comprised of a mixture of chi and rho aluminas and are termed active because they have high surface areas and will absorb vapors or liquid readily. The active alumina has a specific surface area of 200 to 400 m. /g., measured by the BET method ('Brunauer, Emmett, Teller, IACS, vol. 60, p. 309 of 1938).

This active alumina powder is then formed into the desired shapes, i.e., nodules, pellets and the like. Preferably, the alumina is nodulized with water to the desired size in a suitable pan nodulizer. The weight ratio of alumina powder to water is usually about 22-1, respectively. The alumina nodules are generally formed to within a size range of from about 6-8 mesh (Tyler Screen Scale). However, any size desired can be made and, as stated above, other shaped particles can be formed, such as pellets and the like.

After the alumina has been formed, i.e., nodulized, the moist alumina is then hydraulically hardened or cured in a closed container. During the time the nodules are in the closed container, which is usually from about 1 to 4 hours, a rapid transformation of a minor portion of the active alumina to the seudoboehmite form (Al O .XH O wherein X is a value greater than 1 and less than 2) occurs. Pseudoboehmite is a transition aumina similar to boehmite, but it has a smaller crystallite size, generally a larger specific surface area and a larger d (020) spacing byX-ray than that of boehmite. Pseudoboehmite has been discussed in the literature in J. Chem. Phys., vol. 55, pp. 341-53 (Thermal and Hydrothermal Transformations of Alumina by Tertian, R and Papee, D.). This transformation of a minor part of the nodulized active alumina to the pseudoboehmite form results in, among other things, hardening of the alumina nodules so that they are self-sustaining bodies and are capable of retaining their shape when placed in a stream of circulating water or in a pressure vessel containing Water. Heat is generated during' the hydration of the alumina, and without any external source of heat, the temperature in the closed container can reach 100 C. or higher, if steam is not released, An external source of heat may also be applied to the alumina in addition to the heat of hydration, by placing the container in an oven. The higher the temperature in the container, the shorter the time required to form 4 a self-sustaining alumina body containing an appreciable amount of pseudoboehmite.

When the nodules are sufiiciently hardened to form self-sustaining bodies, they are placed in circulating water maintained at a temperature range of from about 60 C. to about 100 C. for a period of time (e.g., of the order of 8 to 48 hours depending on the temperature) until a major portion of the transition alumina has been converted to the seudoboehmite form. Preferably, the temperature of the Water is maintained within the range of from about C. to C., and optimum results are produced when the water temperature is about 90 C. This subsequent hardening treatment increases the proportion of pseudoboehmite in the hydrated alumina. The rate of transformation to the seudoboehmite form is accelerated when the temperature of the water is increased. Satisfactory results are obtained when at least 50%, or a major portion, of the hydrated alumina has been converted to the pseudoboehmite form. Preferably, at least about 70% to 75% conversion of the hydrated alumina to the seudoboehmite form produces optimum results. During this step the soda content of the alumina may also be lowered considerably by replacing the circulating water with fresh, pure water or, alternatively, the soda contaminated water can be passed through an ion exchange column before recirculating said water to the .alumina.

In an alternative embodiment of the invention, a major portion, more than 50%, of the hydrated alumina nodules that have been sufficiently hardened to form self-sustaining bodies may be converted to the boehmite form (Al O .H O) of alumina, rather than the pseudoboehmite form. This can be accomplished by introducing the alumina nodules, after they have been sufficiently hardened to be self-sustaining bodies, into a pressure vessel containing water, and heating the contents to about C. or higher. Here, too, the rate of transformation of the hydrated transition alumina to the 'boehmite form is accelerated with an increase in temperature. For example, it has been found that 6 x 8 mesh (Tyler Screen Scale) alumina nodules are substantially converted to the boehmite form in two hours at a temperature of about 200 C.

The resulting nodules made by either of the two embodiments discussed above are then calcined by gradually heating s-aid nodules to a temperature in excess of about 1000 C. and maintaining them at this temperature for a period of time sufiicient to produce the novel alumina of the invention. For temperatures in the range of 1000 C. to 1300 C. the time of calcining said nodules at the temperature will range from about 70 hours to 10 minutes. Preferably, the calcination is accomplished at a temperature in the range of 1100 C. to 1300 C. wherein the time to form the novel alpha alumina is 4 hours or less. The pore volume of the alpha alumina shaped bodies is such that the major portion thereof is distributed in pores having diameters greater than 580 A. In view of this pore volume distribution, it would be expected that the alumina nodule would have very low resistance to crushing and low attrition resistance. However, as illustrated from the data disclosed hereinbelow, it is shown that the novel alpha alumina particles produced according to this invention have, in addition to the desirable pore characteristics, a surprisingly high crushing strength, i.e., in excess of 10 pounds per nodule (based on 6 x 8 mesh particlesTyler Screen Scale), and a high abrasion resistance.

During calcination there is usually a small change in pore volume of the nodules, but a substantial change in pore volume distribution. This means that even though surface area decreases with increasing calcination temperature, it is the :area provided by the extremely small pores which is being lost, and the volume of these pores is small compared to the total pore volume. The small change in pore volume is apparently due to the formation X-r-ay diffraction analysis of the nodules indicated that of a relatively few large pores at the expense'of many they contained 10% bayerite, 71% pseudoboehmite, and small pores :and attendant passageways. 0.01% Na O.

It is apparent that the specific process described above The nodules were then removed from the water and is subject to numerous modifications, and in order to fur- 5 calcined by gradually heating to temperatures ranging ther illustrate the nature of the invention, the following from 1000 C. to 1300 C. for times varying from 1 hour examples may be taken as illustrative and not 'by way of to 60 hours. Tables I-A and I-B below list the physical limitation thereof. properties of the alpha alumina nodules after calcination.

, TABLE 1-A Heat treatment Surface Crushing Pore volume, cc./g. Sample No. area, mJ/g. strength, 1b.] True dens.,

Temp., C. Time, hr. nodule 2 g./cc. Macro Micro Total 3 1, 000 1 90. 3 4s. 6 3. 51 0. 032 0. 410 0. 492 1, 000 4 53. 2 27. 7 3. 5e 0. 089 0. 401 0. 490 1, 050 1 7s. 9 44. 7 3. 54 0. 07s 0. 402 0. 450 1, 050 4 44. s 22.8 3. S6 0. 177 0. 269 0. 446 1,110 1 44.8 33. s 3. 66 0. 104 0. 372 0. 476 1,100 4 21. 2 18.6 3.72 0. 325 0.110 0. 436 1,100 60 25. 3 11.4 3. 77 0. 413 0.067 0. 430 1,150 1 19. 22. 6 3. 34 0. 317 0. 117 0. 434 1,150 4 11.1 19.1 3.99 0. 394 0 022 0.416 1, 200 1 10. 23. 3 3. 88 0. 393 0 0. 393 1,200 4 s. 3 22.1 3. 99 0. 394 0.022 0. 404 1, 250 1 10.2 21.7 3. 88 0. 398 0 0. 39s 1, 250 4 5. 2 2s. 9 3. 9e 0. 344 0 0. 344 1, 300 1 5. 5 25. 3 3.89 0. 383 0 0. 383 1,300 4 4. 7 2e. 5 3. 92 0. 350 0 0. 350

1 XRD analyses: 2 The crushing strength per nodule refers to the weight required to (a) (It-A1203, Tr; k-Alzoa, M; (ha-A1203, \4. cause a single nodule to abruptly collapse between two flat surfaces.

(b) fl-AIZOQ, M; k-Al202, Mr; Bat-A1203, 1W The crushing strength is based on 6 x 8 mesh nodules.

(c) a-AIZOK, M; transition phases, Mr to Tr. 3 The volume listed under macro is that volume comprised of pores (d) rte-A1203, M; transition phases, Tr. having a diameter greater than 580 A. while the pore volume listed under (e) (2-A1203, M; transition phases, Mr. micro is that volume comprised of pores having a diameter less than (t) (It-A1203, M; transition phases, PTr. 580 A.

M=major, Tr= trace, PTr=possib1e trace, Mr=minor.

TABLE IB.PORE VOLUME DISTRIBUTIONPERCENT OF TOTAL FORE VOLUME IN PORES 0F DIAMETER GREATER THAN STATED SIZE IN MICRONS Sample No. 31. 8 16. 7 8. 9 3. 9 2. 5 1. 5 0. 80 0. 65 0. 34 0. 23 0. 17 0. 12 0. 087 0. 069 0. 058

0 0. 69 1. 38 3. 46 4. 5. 53 7. 84 9. 22 13. 4 15. 4 16. 8 26. 0 43. 0 62. 5 73 1 0 0 1. 2. 41 2. 41 3. 13 6. 25 7. 70 12. 7 14. 7 16. 6 25. 5 59. 9 88. 2 94 6 0 0. 76 2. 26 3. 02 4. 52 5. 29 7. 55 9. 05 14. 1 17. 3 18. 9 30. 7 65. 9 91. 5 9S. 7 0 0. 74 1. 48 3. 08 3. 71 4. 8. 16 9. 65 14. 6 16. 8 19. 8 51. 5 89. 6 98. 5 100. 0 0 1 00 1. 76 2. 77 3. 27 3. 00 9. 55 12. 3 16. 1 l9. 4 25. 6 57. 8 88. O 97. 4 100. 0 0 1. 75 2. 61 3. 20 4. 07 9. 3O 10. 8 15. 7 20. 0 30. 0 83. 4 96. 5 99. 2 100. 0 O O. 78 1. 3O 2. 87 3. 30 4. 18 6. 86 9. 66 15. 4 18. 8 26. 7 65 0 91. 0 98. 0 100. 0 0 1. 14 2. 57 3. 71 4. 57 9. 3 10. 9 16. 5 22. 9 44. 9 93. 7 99. O 100. 0 100. 0

1 Porosity measurements were made with an Aminco-Winslow Porosimeter (American Instrument Co., Inc.). This Porosimeter is based on the mercury intrusion principle whereby samples are immersed in mercury and subjected to varying degrees of pressure. The amount of mercury forced into the pores of the material is measured at specific pressure intervals. Pressure and volumetric readings can be plotted then on semi-log graph paper from which pore diameter and penetration can be extracted directly.

Example A From Tables I-A and I-B above, it can be seen that A q i f ibb i alumina (A12O33H2O), Product when high pseudoboehmite alumina is calcined accordof a Bayer plant, was heated at 815 C. quasi-instantaneto the lhventloh, a lq POFUQH 0f h P Volume ously in a hot gas stream. The resulting calcined alumina 15 made p of Pores having P dlametel: g was separated from the gas stream and then ground on a than 580 for Sample 6 through lh'chlslve- 'hammermilLuntila product having 80%-20 micron par- In the case of Sample 1 thrcfugh 5 lhcluslve ticle size was obtained. This material was then identified though h crushmg st rehgths are hlgh, the tefhperathl'es by X ray infraction analysis and found to contain the and/ or times of calcimng have not been sufiicient to prochi-rho forms of active alumina. This active alumina duce nodules Wherem the malor Pomoh of thg P was formed with water into shaped particles, 6 x 8 mesh is comprised of Pores ing a diameter greater nodules (Tyler Screen Scale) in a pan nodulizer The than 580 A. Sample Nos. 6 through 15 lnclusive have,

alumina to water ratio was 21 These nodules wfire then in addition to the satisfactory pore characterictics, satissealed in cans at room temperatu f 11 hours. The factory high crushing strengths ranging from 11.4 lbs./

heat of hydration was Such, that in this time, the nodules nodule for Sample No. 7 to 28.9 lbs/nodule for Sample were heated to 80 C. or slightly higher, causing them to be self-sustaining and sufficiently hard due to the for- Example B million of appreciable Pseudohoehmhe, 50 that y C(Jllld A preparation similar to that described in Example A be immersed in a str am of Wat r nd r a n their was made, except that the fresh nodules were left sealed shape. in a container for 3 days at room temperature before It is to be noted that there is considerable latitude in placing them in circulating Water at 90 C. After 2 days, the manner in which the pseudoboehmite may be formed in circulating water, X-ray diffraction analysis indicated in the finished nodule. For example, the fresh nodules in the alumina contained 24% bayerite and 54% pseudoa sealed container can be placed in an oven at 80 C. or boehmite. These nodules were gradually heated to 1100 higher to accelerate the development of pseudoboehmite C. and 1200 C. in about 3 hours and then maintained in the nodule before they :are immersed in water. at this temperature for the times indicated. Table 11 lists The nodules were then placed in a circulating stream the physical properties of the alpha alumina nodules of water maintained at a temperature of about 90 C. for after calcination in which a major portion of the pore about 48 hours. Soda content was continuously removed 5 volume is made up of pores having a pore diameter from the alumina by circulating fresh water there through. greater than 5 A.

TABLE I1 Crushing Pore volume Heat treatment Surface strength, True dens, 'XRD analyses area, mfl/g. lb./nodule. Macro, Micro, g./cc. Temp, C. Time, hr. cc./g. cc./g. V I

1, 100 4 24. 8 15.7 0. 305 0. 152 3. 76 a-AlzOa, M; k- 120;, Mr;

I (ha-A1203, M1. 1, 200 1 13.2 17. 4 cit-11341203, M; transition aluminas,

Example C A catalyst that is used to oxidize exhaust gases of inter- Boehmite nodules were prepared accroding to the process described above in Example A, with the exception that the self-sustaining nodules from the sealed containers were placed in a pressure vessel containing water and heated to 120 C., rather than in a circulating stream of heated water. The nodules of hydrated transition alumina were converted in the pressure vessel to boehmite. nodules, and then calcined at temperatures up to 1300 C. as shown below in Table III. Porosity determinations indicate that a major portion of the pore volume is made up of pores having a pore diameter greater than 580 A.

nal combustion engines should possess the following qualities:

(a) It must effect at least the partial oxidation of carbon monoxide and hydrocarbons contained in the exhaust gases at temperatures as low as about 200 C. in order that reduction in the gaseous components begin soon after starting a cold engine,

(b) The activity of the catalyst should be high enough so that the weight of the catalyst required for an automobile is no more than, for example, 8 to 15 pounds,

(c) The catalyst should be capable of withstanding temperatures as high as 900 C., or more without loss of TABLE IIL-HEAT TREATIVIENT OF BOEHMITE NODULES Heat treatment Surface area, Crushing Pore Volume True dens, Sample No. mi g. strength, lb. gJcc. Temp., C. Time, hr. Macro, cc.lg. Micro, cc./g. Total 1, 000 1 55 17 0. 153 0. 390 0. 543 3. 33 1, 000 48 36 0. 156 0. 378 0. 534 3. 49 1, 000 70 32 14 0. 207 0. 220 0. 427 3. 60 l, 050 63 12 10 0. 387 0. 079 0. 466 3. 72 1, 100 8 23 19 0. 299 0. 106 0. 405 3. 72 1, 100 16 13 17 0. 343 0. 070 0. 413 3. 78 1, 150 1 24 0. 207 0.217 0. 424 3. 52 1, 200 V 14 23 0. 280 0. 105 0. 385 3. 76 1, 200 13 23 0. 301 0. 080 0. 381 3. 76 1, 200 1 11 21 0. 309 0. 061 0. 370 3. 80 1, 300 1 6 22 0. 381 0. 062 0. 443 3. 83 1, 300 4 5 24 O. 342 0. 000 0. 342 3. 87

XRD analysis:

(a) 6, 9, k-M; 6, 0, annoys are high temp. transition phases intermediate between active aluminas and tar-A1203.

M=major, Mrtminor, Tr=trace.

It is to be noted in Table III that Sample Nos. 4 through 13 inclusive exhibit high crushing strengths as well as having pore characteristics such that a major portion of the pore volume is made up of pores having a pore diameter greater than 5 80 A.

Example D TABLE IV Sample A B Nodule size, mesh 6 x 8 6 x 8 Percent total void vol due to pores 580 A in diam 81.1 85. 7 Surface area, mJ/g 23 19 Crushing strength, lb 17 t *XRD analysis-Sample A: Alpha, 65% delta-theta, M to Mr; kappa,

race.

Samples A and B were tested for abrasion resistance in the following manner. A 3-inch-deep bed of nodules, consisting of a 50-50 mixture of Sample A and Sample B, contained over a 6-inch square (36 in?) of 16-mesh screen, was shaken at 1750 cycles per minute with inch of horizontal travel for 100 and 200 hours duration with the following losses through the screen: 0-100 hours, 3.4% and 100-200 hours, 2.4%, for a total for 200 hours of 5.7%

The novel alpha alumina prepared as described above may be impregnated with any suitable oxidation catalyst. Representative oxidation catalysts suitable are, for example, manganese oxide, manganese-silver oxide, cobalt oxide, nickel oxide, chromium oxide, vanadium oxide, etc.

activity at the lower temperatures,

(d) The catalyst must also maintain activity for a specified lengthy operational period,

(c) Be resistant to poisoning from gasoline additives such as lead, boron, phosphates, etc., and most important,

(f) It must be of high strength and high abrasion resistance.

It has been found that the catalysts manganese oxide and mixtures of manganese and silver oxides when impregnated on the novel alpha alumina shaped particles of the invention possess the above characteristics and are especially effective for oxidizing exhaust gases from internal combustion engines.

' The manganese catalyst may be applied to the alpha alumina, prepared as disclosed herein, by impregnating the alumina with a solution of a manganese salt, e.g., Mn (NO Preferably, the concentration of the catalyst on alpha alumina will contain about 25% by weight manganese. Lesser amounts of manganese on the catalyst results in a lower activity, and higher amounts do not substantially increase the activity over that obtained with a 2-5% manganese concentration. Therefore, although the preferred concentration of the manganese catalyst is from 25%, lower or higher concentrations can also be used. Alternatively, a quantity of silver may be added to the alumina in combination with manganese and, therefore, the alpha alumina is impregnated with a mixture of a solution of Mn (NO and AgNO Preferably, the manganese and silver concentration of the solution are such as to give a 2-7% by weight manganese and an 0.11% by weight silver concentration in the final catalyst on the alpha alumina, however, higher and lower concentrations are operable.

The manganese catalyst is applied to the carrier by immersing the alpha alumina in a salt solution of the 9 -10 catalytic material, thus impregnating the carrier with the for oxidation activity in an experimental reactor consistcatalyst. For example, when manganese oxides are iming of a 1% inch I.D. Vycor tube which was externally pregnated on the alumina support, a solution of mangaheated. Gases, entering the reactor through the bottom, nese nitrate is prepared and the alumina is immersed in were preheated by a layer of Vycor chips, and then passed the manganese nitrate solution. To assure homogeneous up through about 1 /2 inches of catalyst bed. A thermoimpregnation of the manganese on the alumina, the salt couple in a Vycor well was placed about inch down solution may be acidified with nitric acid so that any basic into the bed. Samples of gases were taken both before constituents of the nodules are neutralized, thus preventand after the reactor by Dynapumps which in turn fed the ing the precipitation of manganese hydroxide at localized analytical instruments, i.e., the flame ionization detector centers. Then, too, the rate of impregantion of the cataand gas chromatograph. lyst on the carrier can be increased by drawing a vacuum Catalytic activity of the nodules is shown below in on the nodules to remove air contained in the pores of the Table V and therein compared with an oxidation catalyst alpha alumina base. After the manganese salt is applied (referred to in Table V as x catalyst) referred to in to the alpha alumina, the carrier and catalyst are heated Thermal Considerations in Exhaust Emission Control at an elevated temperture, e.g., about 850 C. to 950 C., Systems, C. M. Heinen; Society of Automotive Enfor a period of time to produce a catalyst of high catalytic gineers, Paper No. 486 I presented at National Automoactivity. The time of heating will range, for example, bile Week, Mar. 12-16, 1962; Detroit, Mich.

TABLE V Metal oxide Pretreatment of Percent reacted at as metal, Method of catalyst Surface temp., Catalyst Percent on impreg. of area, mfl/g. Gas Tested base (Mn) metal N0 Ttilme, Tgrgp 200 250 300 400 X Hydrocarbons 36 51 64 84 CO 36 51 64 84 Mn on alpha alumina from 6. 4 15 915 8 5 74 84 99 high pseudoboehmite. 0 91 7 99 100 Mn on alpha alumina from 3. 3 8 870 11 76 88 99 boehmite. 17 88 100 100 1 15 min. impreg. under vacuum. from about 10 hours to 1 hour for the temperature range Example F glven' l rancdl i t; z if p i g g Alpha alumina prepared as described above in Example i at y or 3 2: 2 liednto :5 alumigna A was impregnated with a mixture of a solution of manat e manganese S o e pp ganese nitrate and silver nitrate to provide an amount of and heated 2 g 5 f s manganese and silver oxides equivalent to 4.3% by the metal 0 owe y Impregna mg e 81 Ver n weight maganese and 0.29% by weight silver on the alpha 32;? and hkewlse heatmg to dewmpose [the Salt to alumina base. The solution contained sufi'icient HNO to e neutralize any alkali in the nodules. The alpha alumina mvenm}; 1S furflller 3 g gz ig g f z; nodules were heated at about 870 C. for 8 hours. ionowmg sfecl 1c 5' a1 ha Catalytic activity was tested in a 1 /2 inch I.D. Vycor yst 111 com ma on W1 c e 40 tube as described in Example E above and the results are mma 1n high temperature systems involving the oxidation Shown in Tabla VL i carbqn monoxlde and hydrocarbons emmed by gaso- A further sample of alpha alumina, derived from a me engmes' E 1 E pseudoboehmite precursor was impregnated by applying XamP e manganese nitrate and silver nitrate solutions to the alpha Fifty gram samples of alpha alumina nodules, one prealumina base singularly. First, the alpha alumina was pared from a pseudoboehmite precursor as in Example A impregnated with manganese nitrate to provide a manand the other prepared from a boehmite precursor as in ganese oxide content equivalent to 2.3% Mn when heated Example C, were each immersed in 100 ml. of 100 g.p.l. to 870 C. for 3 hours. Then the sample was impregnated of manganese nitrate. with silver nitrate to provide a silver oxide content Homogeneous impregnation of the manganese nitrate 0 equivalent to 0.35% Ag when heated to 870 C. for solution was obtained by acidifying the solution with 1 N about 8 hours. HNO in order to neutralize the basic constituents of the Catalytic activity was tested in a 1 /2 inch I.D. Vycor alpha alumina nodules, thus preventing the precipitation tube as described in Example D above and the results of manganese hydroxide at localized centers. The rate of are shown in Table VI. In Table VI the samples are comimpregnation may be increased by drawing a vacuum on pared to the x catalyst which is described in Exthe nodules to remove air contained in the pores of the ample E.

TABLE VI Metal Pretreatment of oxide as Method of catalyst Surface Percent reacted at temp., 0. Catalyst metal impreg. of area, Gas Tested percent metal N 03- Time, hr. Temp., mJ/g. 200 250 300 400 on base C.

Hydrocargons. 36 51 -64 84 c0 3s 51 e4 84 Mn and Ag on alpha alumina 4.3 Mn- Mixed nitrates.-.- 8 870 1 .6 Hexane 42 56 s 95 from high pseudoboehmite. 0.29 A2 C0... 94 100 100 100 Mn and Ag on alpha alumin' a 2.3 Mn Mn(NO3), 1st.--" 3 870 9-2 Hexane 34 44 74 98 from boehmite. 0.35 Ag Ag(NOs)2, 2nd.... 8 87 CO 100 100 100 alumina base. It is to be understood that various changes and modifica- After the nodules were impregnated with manganese tions may be made in the foregoing invention without nitrate they were separated from the solution. The im- 70 departing from the spirit of the invention and the scope pregnated nodules were then calcined at the times and of the appended claims. temperatures shown in Table V. After calcination of the What is claimed is: catalysts, XRD analysis showed the presence of Mn O 1. A method for preparing alpha alumina shaped bodies M11 0, and MnO.Al O which comprises:

The alpha alumina impregnated catalysts were tested (a) passing particulate alumina trihydrate rapidly :11 I through a stream of hot gases maintained at .a temperature not .less than about 800 C, for not more than about ten seconds to form an activealumina comprising a mixture of chi and rho forms of alumina sutficient to produce an alpha alumina havinga pore volume distribution such that a major portion of the pores have a diameter greater than 580 A. and a crushing strength not less than about ten pounds per having a specific surface area of about 200-400 particle, said strength based on 6 x 8 mesh particles. mP/g. and, 4. In the method for preparing alpha alumina shaped (b) forming the active alumina with water into shaped particles especially adapted for use as a catalyst support bodies and rehydrating and hardening said bodies in by impregnating alpha alumina with an oxidation catalyst, a closed container so that they will become selfthe improvement Which comprises:

sustaining, 10 (a) passing particulate alumina trihydrate rapidly (c) converting a major portion of the rehydrated through a stream of hot gases to form an active alumina to an alumina phase selected from the group alumina comprising a mixture of chi and rho forms consisting of pseudoboehmite and boehmite, or mixof alumina, tures thereof by contact with water, and (b) forming the active alumina with water into shaped (d) calcining the alumina at a temperature in excess Par iCl of about 1000" C. for a period of time sufficient to (c) hydraulically hardening the active alumina partiproduce an alpha alumina having a pore volume discles by placing them in a closed container for a period tribution such that a major portion of the pores have of time sufiicient for the heat of hydration to pro- 3. diameter greater than 580 A, and a crushing strength mote a sufiicient amount Of pseudoboehmite to not less than about ten pounds per body, said strength render the particles self sustaining, b d on 6; X 8 me h bodi (d) subjecting the particles to a further hardenin 2. A method for preparing alpha alumina shaped partreatment at a temperature in the range of 60 C. to ti l hi h comprises; about 100 C. for about 8 to 48 hours in the presence (a) passing particulate alumina trihydrate rapidly of ir g Water,

through a stream of hot gases maintained at a tem gradually heating the particles, to a temperature perature not less than about 800 C. for not more in the vrange of about 1000 to 1300 and h about ten seconds to fo an active l i calcining the particles at said temperature for a period h i a ifi rfa area of b 2Q() 4QQ of time sufficient to produce an alpha alumina having m. g. and comprising a mixture of chi and rho forms a P Volume distribution Such that a major PQ f alumina of the pores have a diameter greater than 5 80 A., and (b) forming the active alumina with Water into shaped a crushing Strength not less than about ten Pounds pal-ticles, per particle, said strength based on 6 x 8 mesh par- (c) hydraulically hardening the active alumina particles 616$ i by placing them in a closed container fOr a period f S. The method according to clarm 4 wherein the oxidatime suflicient for the heat of hydration to promote catalyst 15 mangahes? asuificient amount of pseudoboehmite to render the t The meihod aFcordlhg to clalm 4 Whereln the OXldaparticles selflsustaining tron catalyst is a mrxture of manganese and silver oxides. (d) converting a major portion of the alumina t0 the 7. In the method for preparing catalyst-impregnated pseudoboehmite phase by contacting said alumina alpha alulllma a d Panlcles by {mpregnatlhg 12 with circulating Water maintained Within a tempera alumina with an oxidation catalyst, the improvement which ture range of from 60 C. to about 100 C., and compnses: r (e) gradually heating theparticles to a temperature in (a) Passmg Pamwlate alumma tflhytdrate rapidly v the range of about 10000 to 13000 and cab through a stream of hot gases maintained at a temcining the particles at said temperature for a period perature not less than about not time suflicient to produce an alpha alumina having than about ten seconds to form an active alumrna a pore volume distribution such that a major portion hagmg a speclfic, surface area of 'f 200-400 ofthe pores have a diameter greater than 580 A. and a Compnsmg a mlxture of and rho forms a crushing strength not less than about ten pounds of l Q per Particle, said Strength based on 6 X 8 mesh (b) forming the active alumina Wrth vvater into shaped Particles. particles and rehydrating and hardenmg said particles A method for preparing alpha alumina Shaped pap 1n a closed container until they are self-sustaining, ticles especially adapted for use as a catalyst support (c) collvertmg a malor of the hydra/fed which comprises: alumina to the pseudoboehmrte phase by contacting (a) passing particulate alumina trihydrate rapidly 531d ll gnna Wrth clrculaglng water heated to from through a stream of hot gases maintained at a tem about to perature not less than about 800 C. for not more (d) i heatmg partlcles to a temoperamre than about ten seconds to form an active alumina i the range about 9 to 1300 and having a specific surface area of about 200-400 cakfmmg {he partlqles at sald temperature a m. and comprising a mixture of chi and rho forms penpd of tune Sufiic1ent.t P q an alpha alumina of :zrzazrrssztaast te: 3:: 1 me er a er an g fg i the acnve alumma wlth water Into shaPed 580 A., and a crushing strength not less than about (6) hydraulically hardening the active alumina particles 'ifig fi gg gz gz sald Strength based on 6 X 8 by placing them m a closed container for a period of w (e) impregnating the alpha alumina with a catalyst time sufficient for the heat of hydration to promote a sufiicient amount of pseudoboehmite to render the 'particles self-sustaining. 1 (d) subjecting the particles to a further hardening treatment at a temperature in the range of 60 C. to about C. for about 8 to 48 hours in the presence of circulating Water, and (e) gradually heating the particles to a temperature in the range of about 1000 C. to 1300 C. and calcining the particles at said temperature for a period of time selected from the group consisting of manganese and manganese and silver salts and heating the impregnat'ed alumina for about Sto 4 hours within a temperature range of from about 870 C. to 920 C.

8. A method for preparing alpha-alumina shaped particles especially adapted for use as a catalyst support which comprises:

(a) passing particulate alumina trihydrate rapidly through a stream of hot gases maintained at a tem- 7 5 perature not less than about 800 C. for not more 13 than about ten seconds to form an active alumina having a specific surface area of about 200-400 m. g. and comprising a mixture of chi and rho forms of alumina,

(b) forming the active alumina with Water into shaped particles and rehydrating and hardening said particles in a closed container until they are self-sustaining,

(c) converting a major portion of the alumina to the boehmite phase by contacting said alumina with water in a pressure vessel at a temperature above about 120 C., and

(d) gradually heating the particles to a temperature in excess of about 1000 C. and calcining the particles at said temperature for a period of time suificient to produce an alpha alumina having a pore volume distribution such that a major portion of the pores have a diameter greater than 580 A., and a crushing strength not less than about ten pounds per particle, said strength based on 6 x 8 mesh particles.

9. A method for preparing alpha alumina shaped particles especially adapted for use as a catalyst support which comprises:

(a) passing particulate alumina trihydrate rapidly through a stream of hot gases maintained at a temperature not less than about 800 C. for not more than about ten seconds to form an active alumina having a specific surface area of about 200400 m.*/ g. and comprising a mixture of chi and rho forms of alumina,

(b) forming the active alumina with water into shaped particles and rehydrating and hardening said particles in a closed container until they are self-sustain- (c) converting a major portion of the alumina to the boehmite phase by contacting said alumina with water in a pressure vessel at a temperature above about 120 C., and

(d) gradually heating the particles to a temperature in the range of about 1000 C. to 1300 C. and calcining the particles at said temperature for a period of time sufiicient to produce an alpha alumina having a pore volume distribution such that a major portion of the pores have a diameter greater than 580 A., and a crushing strength not less than about ten pounds per particle, said strength based on 6 x 8 mesh particles.

10. In the method for preparing alpha alumina shaped particles especially adapted for use as a catalyst support by impregnating alpha alumina with an oxidation catalyst, the improvement which comprises:

(a) passing particulate alumina trihydrate rapidly through a stream of hot gases maintained at a temperature not less than about 800 C. for not more than about ten seconds to form an active alumina having a specific surface area of about 200-400 m. g. and comprising a mixture of chi and rho forms of alumina,

(b) forming the active alumina with Water into shaped particles and rehydrating and hardening said pa1ticles in a closed container until they are self-sustains,

(c) converting a major portion of the boehmite phase by contacting said alumina with water in a pressure vessel at a temperature of about 120 C.,

(d) gradually heating the particles to a temperature in the range of about 1000 C. to 1300 C. and calcining the particles at said temperature for a period of time sufficient to produce an alpha alumina having a pore volume distribution such that a major portion of the pores have a diameter greater than 580 A. and a crushing strength not less than about tend pounds per particle, said strength based on 6 x 8 mesh particles.

11. The method according to claim 10 wherein the oxidation catalyst is manganese oxide.

12. The method according to claim 10 wherein the oxidation catalyst is a mixture of manganese and silver oxides.

13. In the method for preparing catalyst impregnated alpha alumina shaped particles by impregnating alpha alumina with an oxidation catalyst, the improvement which comprises:

(a) passing particulate alumina trihydrate rapidly through a stream of hot gases maintained at a temperature not less than about 800 C. for not more than about ten seconds to form an active alumina having a specific surface area of about 200-400 m. g. and comprising a mixture of chi and .rho forms of alumina,

(b) forming the active alumina with Water into shaped particles and rehydrating and hardening said particles in a closed container until they are self-sustain- (c) converting a major portion of the alumina to the boehmite phase by contacting said alumina with water in a pressure vessel at a temperature of about C.,

(d) gradually heating the particles to a temperature in the range of about 1000 C. to 1300 C. and calcining the particles at said temperature for a period of time sufficient to produce an alpha alumina having a pore volume distribution such that a major portion of the pores have a diameter greater than 580 A. and a crushing strength not less than about ten pounds per particle, said strength based on 6 x 8 mesh particles, and

(e) impregnating the alpha alumina with a catalyst selected from the group consisting of manganese and manganese and silver salts and heating the impregnated alumina for about 8 to 4 hours within the temperature range from about 870 C. to 920 C.

References Cited UNITED STATES PATENTS 2,758,011 8/1956 Bloch 23143 2,773,844 12/ 1956 Carlson et al 252463 2,881,051 4/1959 Pingard 23-143 2,901,441 8/ 1959 Waterman 252463 3,222,129 12/1965 Osment et al. 23141 3,223,483 12/1965 Osment 23-l43 3,226,191 12/1965 Osment et al. 23141 3,251,783 5/1966 Keith et al. 252463 2,800,518 7/1957 Pitzer 23143 X 3,305,492 2/1967 Ameen 252463 3,310,366 3/1967 Koepernik 23143 X OTHER REFERENCES Newsome et al., Alumina Properties, Technical Paper No. 10, Aluminum Co. of America, Pittsburgh, Pa., pp. 34, 46.

OSCAR R. VERTIZ, Primary Examiner.

MAURICE A. BRINDISI, HERBERT T. CARTER,

Examiners. G. OZAKI, Assistant Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,392,125 July 9, 1968 Allan C. Kelly et al.

It is certified that error appears in the above identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, line 55, "aumina" should read alumina lines 71 and 72, "released," should read released. Columns 5 and 6, TABLE I-A, fourth column, line 5 thereof, "44.8" should read 48.8 same columns 5 and 6, TABLE I-B, tenth column, line 5 thereof, "11.5" should read 11.6 same table, same column, line 6 thereof, "11.4" should read 11.7 same table, same column, line 10 thereof, "14.1" should read 15.1 Column 9, line 10, "impregantion" should read impregnation line 15, "temperture" should read temperature line 38, cancel "illustrated", second occurrence. Column 10, line 35, "maganese" should read manganese Columns 10 and 11, TABLE VI, seventh column, line 1' thereof, "Hydrocargons" should read Hydrocarbons same table, eighth column, line 6 thereof, "70" should read 79 Column 11, line 4-, beginning with "comprising" cancel all to and including "m. /g, and," in line 6, same column 11, and insert having a specific surface area of about 200-400 m. Z/g. and comprising a mixture of chi and rho forms of alumina, Column 14, line 3, "tend" should read ten Signed and sealed this 7th day of April 1970.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. WILLIAM E. SCHUYLER, JR. Attesting Officer Commissioner of Patents 

